PL201703B1 - Reverse molded panel - Google Patents

Abstract

The subject of the invention is a product made of a two-way shaped wood composite and a method of producing it, as well as a set of wainscoting and a two-way shaped door lining, and its forming method, as well as a door containing a door lining. The product according to the invention has a first flat surface part (20, 22, 24 26) surrounding an outwardly projecting second flat surface part (13), the first and second flat surface parts (13, 20, 22 , 24 26) have an essentially uniform density and the second part of the flat surface (13) has many external corners (15) that imitate the surface structure of natural wood, with the rear surface (34) co-planar , 36) of the product allows it to adhere to a base with a flat surface (37), and the fact that the product has an internal and upwardly contoured part (14), located between and connecting mutually the first and second parts with a flat surface (13, 20, 22, 24 26), with the contoured part (14) having a higher density than the density of the first and second parts with a flat surface ( 13, 20, 22, 24 26). PL PL PL PL

Description

(12) PATENT DESCRIPTION (19) PL (11) 201703 (13) B1 (21) Filing number: 358268 ⁽¹³⁾ (22) ^{Filing date: 01/09/2001 (51) Int.Cl.}

B27N 7/00 (2006.01) (86) Date and number of international application: B27M 3/08 (2006.01)

2001-01-09, PCT / US01 / 00593 B27D 1/08 (2006.01) (87) International application publication number and date:

2001-11-01, WO01 / 81055 PCT Gazette No. 44/01

Bi-directionally shaped composite wood product and the method of its production (54) as well as a set of paneling and a two-way shaped door cladding and its method of forming, as well as a door containing a door cladding

(73) The right holder of the patent: (30) Priority: MASONITE CORPORATION, Tampa, US 2000-04-20, US, 60 / 198,709 2000-12-21, US, 09 / 742,840 (72) Inventor (s): Steven K. Lynch, St. Charles, US (43) Application was announced: 09.08.2004 BUP 16/04 Dale E. Schafernak, Palatine, US Karine Luetgert, Geneva, US Bei-Hong Liang, Naperville, US Lee Braddock, Huntley, US (45) The grant of the patent was announced: April 30, 2009 WUP 04/09 (74) Representative: Misztak Irena, PATPOL Sp. z o.o.

⁽⁵⁷⁾ The subject of the invention is a bidirectionally shaped composite wood product and a method of its production, a paneling set and a bidirectional shaped door cladding and its forming method, as well as a door comprising a door cladding. The product of the invention has a first planar portion (20, 22, 24 26) surrounding an outwardly projecting second planar portion (13), the first and second planar portion (13, 20, 22, 24, 26) having a substantially uniform density and the second flat surface portion (13) has a plurality of outer corners (15) that simulate the surface structure of natural wood, the coplanar rear surface (34, 36) of the product allowing it to adhere to the flat surface substrate (37). and in that the article has an upwardly facing contour portion (14) interposed between and interconnecting the first and second planar surface portions (13, 20, 22, 24, 26), the contoured portion (14) having a higher density than the density of the first and second flat surface portions (13, 20, 22, 24, 26).

PL 201 703 B1

Description of the invention

The subject of the invention is a bi-directional shaped wood composite product and a method of its production, a set of paneling and a two-way shaped door cladding and its method of forming, as well as a door comprising a door cladding. A bi-directional shaped (when shaped upwards profiled) wood composite product is used especially for the production of wainscot panels and as a top layer or cladding surface of a door, as well as a method of two-way shaping of a complex wooden product by shaping an upwardly directed profile from the part of the product having flat base.

Man-made boards such as fibreboards, e.g. hard fiber boards, are usually concave-shaped on the main visible outer surface during the manufacture of interior, exterior panels, and particularly in the manufacture of door cladding such that the outer surfaces, e.g. the highest structure of the pressed product. The prior art reveals that it is difficult to reverse shaping and emboss deep patterns in a panel due to stretching and breaking of the fibers. A bidirectional shaped fibreboard is stretched more on its outer surface than on its inner surface (in contact with the shaped surface upwards), which makes bidirectional shaping difficult when you want a clear, firm pattern on a raised panel that imitates embossing in a natural wood. As disclosed in the following US patents, bi-directional forming and deep-pattern embossing in a fibreboard panel requires one or more multiple embossing, curing at elevated temperatures, film compactness, or a large amount of resin in a portion of the outer surface and / or a high amount of resin. a resin binder comprising about 5-25% and at least 10% of the total weight of the article. This applies to patents with numbers 4,061,813 Geimer, 4,378,265 Kiss, 4,552,797 Munk, 4,610,900 Nishibori, 4,612,224 Davis, 4,622,190 Schultz, 4,726,881 Schultz, 4,734,236 Davis, 4,812,188 Hansen, 4,844,968 Persson, 4,378,265, 493, Imeda 4,302,960,548 Davis, 4,365,960,548 Davis, 4,365,960,548. 5,090,173 Coggan, 5,154,968 DePetris, 5,443,891 Bach, 5,851,325 Terada, 5,887,402 Ruggie.

Cellulose fibers used to form a cellulose board, for example a quarter or a half centimeter, preferably 40 mm or 45 mm thick and a specific gravity, for example 0.6, may initially be overdried after drying and fulling, but the cellulose fibers in such boards absorb moisture from the atmosphere and typically contain 2% to 10% moisture when shaped by hot stamping, depending on the humidity of the place where they are stored and / or manufactured.

Bi-directional shaped panels are especially useful as wainscot panels. They are bi-directionally shaped to obtain an upward profiled layout. This arrangement allows the panel to be fixed directly to the wall, unlike the prior art method requiring retainers (see Fig. 6A), thus allowing easy installation coupled with excellent aesthetics of the paneling panel. The old ways of treating natural wood are well-established and expensive. Besides the repeated stampings of natural wood, also gypsum and polymeric materials are used in the production of the paneling panels, but commercially these have little acceptance as they do not have the look and quality of natural wood. There are no bi-directional shaped wood-fiber composite paneling units available that provide the ease of use achieved by the principles of this invention.

The present invention relates to a bi-directionally shaped wood composite article with a mat of refined cellulose fibers and a suitable high tack binder that combines the cellulosic fibers into a solidly structured product with a specific gravity in the range from about 0.96 to about 1.08.

The essence of the invention is that the product has a first planar portion surrounding an outwardly projecting second planar portion, the first and second planar portion having a substantially uniform density and the second planar portion having a plurality of outer corners. which imitate the surface structure of natural wood. The coplanar rear surface of the article allows it to adhere to a substrate with a flat surface. Moreover, the article has an inner and upward contoured portion interposed between and interconnecting the first and second planar surface portions, the contoured portion having a higher density than that of the first and second planar portions. Preferably, the composite wood article comprises less than 5% by weight of a resin binder, with the resin binder evenly distributed throughout the product.

PL 201 703 B1

The composite wood product according to the invention has no thermoplastic coating material on the cellulose board and no resin impregnated paper coating, and the cellulose fiber board is produced by a dry process and has smooth, flat backs.

The flat wall surface of the article is attached to the coplanar rear surface of the article by means of fasteners or an adhesive without the use of adjusting spacers between the planar wall surface and the coplanar back surface of the article.

Preferably, the outwardly projecting contoured portion projects outwardly from the surrounding first planar portions by a distance of 5 to 10 mm.

The cellulose board contains at least 40% by weight of softwood fibers, based on the total weight of cellulosic fibers in the product, wherein the softwood fibers are pine, spruce and a mixture thereof, and cellulose fibers are about 100% by weight of the softwood fibers.

The contoured portion projects outward and inward from the surrounding first portion with a flat surface at an angle ranging from 25 ° to 35 °, preferably at an angle ranging from 30 ° to 35 °.

The specific gravity of the article at the highest point in the contoured portion is higher than the specific gravity of the first flat surface portions, the specific gravity of the article at the highest point ranges from 1.02 to 1.08 and the specific gravity of the first planar portions ranges from 0.98 to 1.00.

The invention also relates to a method of making a bi-directional shaped wood composite product in which the cellulose fiber mat and the resin binder are placed on a substantially horizontal, lower shaping mold.

In accordance with the invention, the lower shaping mold has flat surface portions surrounding an upwardly projecting contour pattern imitating a surface structure and having a plurality of outer corners, the mat is then pressed against the upper shaping mold. The form is contoured internally on the bottom face contacting the mat, and this interior pattern in the upper shaper mold has a shape complementary to the contour pattern imitating a surface structure and protruding upwardly from the lower shaper so that the density of the mat increases occur at points corresponding to an upwardly projecting surface structure in relation to the density of the mat at points corresponding to parts with a flat surface. Embossing is performed at the appropriate temperature and pressure to structurally consolidate the mat into a specific gravity product ranging from about 0.96 to about 1.08.

Preferably, the article comprises less than 5% by weight of a resin binder and the resin binder is evenly distributed throughout the article, with the article free of the thermoplastic coating material on the cellulose mat and no resin-impregnated paper coating.

The method according to the invention also consists in that the cellulose fiber mat is produced during the dry process and has a smooth, flat back surface, and the flat wall surface is attached to the back surface of the product without the use of adjusting spacers placed between the flat wall surface of the flat back surface of the product. .

The outwardly projecting contour panel is shaped to project from the surrounding flat surface parts 5 to 10 mm above the surrounding flat base.

The cellulose board contains at least 40% by weight of softwood fibers, based on the total weight of cellulosic fibers in the product, wherein the softwood fibers are pine, spruce and a mixture thereof, and cellulose fibers are about 100% by weight of the softwood fibers.

The contour portion is formed as a protruding and concave element with respect to the surrounding planar portion at an angle ranging from 25 ° to 35 °, preferably at an angle ranging from 30 ° to 35 °.

The upper and lower parts of the shaping form are spaced less at the highest points in the convex contours than on the flat surfaces surrounding the convex contours, so that the article has a greater specific heaviness at the highest points of the contoured part than on the flat surface parts surrounding the convex contours.

The specific gravity at the highest points of the convex contoured portion ranges from 0.98 to 1.00, and the specific gravity of the flat-faced portions surrounding the contoured portion ranges from 0.98 to 1.00.

PL 201 703 B1

The invention also includes a method of manufacturing a raised contour panel that is attached to a flat surface into which a wood composite product is formed and then separates the raised panel from the surrounding flat-faced parts.

Preferably, the cellulosic fibers are approximately 100% by weight of softwood fibers.

The invention also relates to a paneling set comprising a first and a second composite wood product, wherein both the first and second composite wood products have the same height but different width and both have outwardly projecting contour panels of the same height and different width, and a third , flat wood composite product. All three composite elements can cover the entire wall between the base plate of the wall with a wall trim at the height of the chair railings by cutting only the third, flat panel to the correct size at the corner of the wall.

The paneling set comprises a first and a second composite wood product, the first and second composite wood products having the same height but different width and both having outwardly projecting contour panels of the same height and different width, and a third, flat composite wood product. wood. All three composite members can cover the entire wall between the wall base plate and the wall trim at the height of the chair railings by cutting only the third, flat panel to the correct size at the corner of the wall.

Preferably, a fourth wood composite product is provided for the paneling set having a plurality of spatial outwardly projecting contour panels and being wider than the first, second, and third wood composite product.

The paneling set has a rectangular electrical outlet cover having slots adapted to cover the rectangular area surrounding the electrical outlet, while the electrical outlet remains accessible for connection of any electrical appliance, and having side walls at least as high as the protruding contour panels being part of the two-way shaped product of the electrical outlet. of the composite wood so that the slits formed to provide an electrical socket cover in the panel of the composite wood product are invisible and come into contact with the cuts in the composite wood product in which they are located.

The invention also relates to a bi-directional shaped wood composite door cladding comprising a shaped composite wood composite panel having a first surface adapted to be mounted exterior and an opposite, a second surface adapted to be attached interior, and adhered to the surface.

The essence of the invention is that the panel consists of a main part with flat surfaces, at least one flat part of the panel lying in a plane remote from the plane of the main part with flat surfaces, and an outwardly contour wall surrounding the flat part of the panel and connecting mutually and integral with the main part of the flat and flat panel part, and the contour wall extends outwardly from and correspondingly to the first surface.

Preferably, the contour wall has an apex which has a rounded top surface, and furthermore the contour wall comprises a plurality of raised flat steps located between the flat-faced main portion and the rounded top surface.

The aforementioned contour wall comprises a first contour portion adjacent to the flat-faced main portion and a second contour portion adjacent the flat panel portion, the first contour portion extending outward from the first surface, and the second contour portion extending inwardly with respect to the planar portion of the panel. .

The flat part of the panel is situated outward with respect to the main part with flat surfaces.

The cladding contour extends outward from the first face at an angle of from about 25 ° to about 35 °, and each portion of the raised flat panel is rectangular.

The door facing has a main portion with flat faces has a first transverse dimension, the contour wall has a second transverse dimension, and the second diameter is smaller than the first.

In the cladding according to the invention, 40% by weight of the panel consists of wood fibers from the group consisting of pine and fir, and the panel is made of fibreboard.

The invention also relates to a method for forming a two-way shaped wood composite door trim consisting of steps in which a shaping mold having an upper shaping shank having a flat portion and at least one shaping recess and a lower shaping shank that has a portion is introduced first. flat and at least one raised contour pattern to complement the shaping cavity. Then a cellulose mat is placed between

The upper and lower shaping mold shafts are pressed together and the cellulose mat is compressed therebetween, and heated to a temperature to form a door lining having a contour portion and a flat portion.

According to the invention, the contoured portion extends outward to the first surface of the planar portion adapted externally and opposed to the second surface adapted to be used internally and being attached to a surface wherein the planar portion has a first transverse dimension and the contour portion has a second dimension. transverse, smaller than the first.

Preferably, the cellulose sheet is compressed to a suitable gravity in the range of 0.96 to 1.08 and heated to a temperature of about 196 ° C to about 232 ° C, with a pressure of about 550 psi to about 850 psi applied to the cellulose sheet. .

The cellulose board contains at least 80% by weight of fibrillated cellulose fibers which come from the group consisting of pine and fir, and the thermosetting binder is selected from the group consisting of melamine-formaldehyde, phenol-formaldehyde and urea-formaldehyde resins.

The bi-directional shaped composite wood panel panel of the invention comprises a main flat portion having a first surface adapted to be attached as an exterior and an opposite second surface adapted to be attached as an interior, which is adhesively attached to the surface.

The panel is characterized in that the main flat part has a first transverse dimension, the flat part of the panel lying on a plane remote from the plane of the main flat part, the contoured part extending outward from and corresponding to the first face and being connected and integrated with the main part. the flat and flat part of the panel and the contoured part has a second lateral dimension smaller than the first.

Preferably, the bi-directional panel comprises a contour portion with a rounded top portion and the flat portion of the panel is adapted to be fitted external to the main planar portion.

In a bi-directional panel according to the invention, the contour portion comprises first and second contour portions and the first contour portion has a rounded upper surface and is approximated to the main flat portion, and the second contour portion is approximated to the flat portion of the panel.

The door of the invention comprises first and second door cladding, each having a first interior surface attached to the door carcass and a second exterior surface.

The essence of the invention is that at least one of the door claddings has a main flat surface and at least one flat panel part lying on a plane remote from the main flat part plane, and an outwardly contoured wall surrounding the flat panel part and is connected and integrated. with the main panel flat part, and with the flat panel part, and the contoured wall extends outward from and corresponding to the first surface.

Preferably, in the door, the main flat surface has a first transverse dimension and the contour wall has a second transverse dimension and the second transverse dimension is smaller than the first, and the flat portion of the panel is adapted to be fitted external to the main flat portion.

The door contour wall comprises a first part which has a rounded top surface approximating the main flat part and the second part approximating the panel part.

The subject of the invention also includes a two-way shaped wood composite door cladding comprising a shaped hard fiberboard panel that has a first surface adapted to be laid outward and an opposite second surface adapted to be used as an interior that can be adhesively attached to the surface, the panel has a flat main portion , at least one flat panel part and an outwardly projecting contoured wall surrounding the flat panel part and connected and integrated with the main flat and flat panel part, and the contour wall extends outwardly from and corresponding to the first surface.

The inventive bi-directional shaped wood composite door trim panel comprises a shaped wood composite shaped panel that has a first surface adapted for external use and an opposite second surface adapted for internal use that can be attached to the surface. The panel includes by weight

From up to about 8% of the resin binder and has a major flat portion, at least one planar panel portion, and an outwardly projecting contoured wall surrounding the flat panel portion and connected and integrated with the main flat panel portion, and the contoured wall extending through the outward from and corresponding to the first surface.

The products according to the invention are adapted to completely cover any size of the wall between the base plate of the wall and the wall trim at the height of the handrails of the chairs.

The method of bi-directional forming a cellulosic plate by single pressing aims to produce one or more relatively high density raised panels where no pre-pressing or other pre-forming action such as skinning is required. The bidirectionally shaped panels are shaped on the traditional multi-opening fibreboard pressing plant by a single pressing process and a perfect reproduction of the mold details (shaping accuracy) is obtained without visible fiber cracks. The panels may include foil, an impregnated paper coating, or a thermoplastic covering material, but do not require a coating or high-resin coating for excellent shaping accuracy and appearance.

The cellulose board is shaped during a dry rather than wet process to provide a smooth, flat back surface surrounding the back surface of the raised, shaped panels such that during the wet process the cellulose sheets are pressed and an inverted pattern is formed. The bidirectionally shaped, raised panel pattern produces a raised profile (convex profile) that has firm and distinct detail at the outer corners, appearing to give the impression of embossed, hand-processed natural wood, being in fact a bidirectionally shaped composite material of high-density wood that it can be attached to a flat wall, for example a gypsum wallboard with an adhesive.

Another advantage of the invention is the provision of bi-directional shaped wood composite products and a method for their manufacture in the form of a kit such that the products can be mounted on any flat surface such as a gypsum wallboard or a plastered wall to fill the entire area between the base plate of the wall and a wall trim at the height of the chair railings, providing firm and distinct details in the outer corners, with the look and feel of embossed, hand-processed natural wood.

In addition, the subject matter of the invention provides that the paneling set consists of a plurality of bi-directional shaped wood composite products of different widths and a flat panel that can be easily cut to the appropriate thickness to fill the entire area between the base plate of the wall and the wall trim at the height of the chair handrails. .

Yet another advantage of the invention is the provision of bi-directional shaped wood composite products that accurately reproduce the contours and details of the outer corners in a single stamping without the need for repeated pressing, curing at elevated temperatures, foil content or a large amount (5-25%) of resin in part of the outer surface .

A composite wood product can be shaped from cellulose boards that do not require the use of synthetic fibers, the layering of short and long fibers, the use of resin-impregnated paper coatings, thermoplastic varnish coatings or puncturing (punching with a needle) to keep the board intact before shaping.

The structure of wood composite products serves to prevent damage and cracks of the surface fibers, and the geometry of this product provides clear and decisive details on the surface, especially at the outer corners of the embossing geometry, in a single embossing (shaping), while ensuring a substantially uniform density everywhere except the rounded top of the raised, shaped, rectangular embossing pattern.

The paneling set according to the invention aims to provide at least two different sizes of the raised panels (windows), at least two different widths of the composite articles, the composite product having a smaller width having a proportionally smaller width of the raised panel, and a flat sandwich panel such that the joint composite products allow the entire area between the base plate of the wall and the wall trim at the height of the chair railing to be filled by cutting the flat sandwich panel so as to fit into the corners of the inner wall to cover the entire width of the wall up to the wall trim at the height of the chair railing. More specifically, the preferred bi-directional shaped articles in the kit are provided in widths of about 30, 41 and 122 cm, and 30 and 41 cm if they include

Various sizes of windows (raised panels) and a product 122 cm wide having three windows sized to match the product 30 or 41 cm wide.

The construction of a bi-directional shaped wood composite product that has one or more raised panels comprising a central flat raised portion surrounded by a rectangular raised embossing pattern, the raised panels being surrounded by flat horizontal and vertical rails, ensures that they can be separated from the surrounding horizontal and vertical stiles, for example by rubbing or sanding, and from the surrounding flat base so that the separated panels can abut against the room entrance doors, furniture doors, shutters, furniture, library and embossed walls, or as the framing material by further sliding the flat, raised portion of the panel.

The subject matter of the invention is illustrated in an embodiment in the drawing, in which Fig. 1 shows the dry-produced cellulose composite sheet in a partial partial section between the lower part of the shaping mold and the upper part of the shaping mold, where the board is so free that towers over the contours of the raised panel belonging to the pre-embossing shaping mold pattern, Fig. 2 - Bi-directional wood composite paneling element on a partial partial section, showing the preferred geometry of the raised panels, Fig. 3 - wainscot assembly components in front view of which they consist there are four different products, i.e. three bi-directional shaped panels and one flat panel, with which you can completely fill the wall space between the wall base and the slat at the height of the chair railing only by cutting the flat panel to a size that allows the entire wall surface to be filled up to the slats at the height of the armrests of the chairs, Fig. 4 - Part of the wall including an oversized window on a partial partial section, showing one way of fitting the assembly of Fig. 3 to a wall with an oversized window, Fig. 5 - a two-way shaped wood composite article on a partial partial section , showing the pattern profile of the two-way shaped raised panel, Fig. 6 - wood composite paneling element adjacent to the wall covered with cladding boards between the base of the wall and the batten at the height of the chair railings, along the line 6-6 in Fig. 7, Fig. 6a - paneling element known from the prior art in a side view similar to Fig. 6, attached to a cladding wall by means of an adjusting spacer, and Fig. 7 a composite wood paneling element attached to the wall in a front view showing a new pattern of the connecting plate which can be attached to the wall by a paneling element even if the mains plug is in the position of the raised panel pattern.

In the illustrated preferred embodiment of the invention, the shaped wood composite products are shaped into wainscot panels that can be attached to a flat inner wall between the base of the wall and the railing lath of the chairs so as to resemble solid natural extruded wood as shown. in Fig. 2. However, it should be understood that the principles of the invention can be used not only in the manufacture of paneling, but also in the manufacture of doors and door cladding, particularly door tops of furniture, and any other shaped, artificial wood composite product that includes one or more a plurality of bidirectionally shaped, raised embossing patterns adhering to flat portions of the surface of the shaped article. Examples of other bi-directional shaped wood composite products that can be manufactured according to the principles of the invention are decorative fibreboards, door coverings for interior and exterior corridors, door coverings for furniture and garage doors, decorative interior wall panels, surface embossing of furniture and sets of furniture, shaped separated panels from surrounding flat parts for attachment to external, flat surfaces of furniture, furniture doors or their flat parts, furniture elements, and others.

The dimensions of the bi-directional shaped composite articles range from about 12 to 244 cm in width and from 30 to 152 cm or even 244 cm in height.

Products made according to the principles of the invention consist of at least 80% by weight of fibrillated cellulose fibers, taking into account the total dry weight of the fibers in the product, and of a binder that enables the fibers to be joined together to form a structurally stable, coherent product. Cellulose fibers are in the form of refined, fibrillated fibers and can be shaped and bonded together with a natural or synthetic binder to provide an aesthetic shaping pattern as well as a smooth or wood grained surface on all exterior visible surfaces, including shaped surfaces, raised panels. The products can be shaped thin, such as 0.25 to 0.75 cm, paneling, and the raised panels can be

Cut or sanded to attach to a door or similar surface and provide a raised, hand-drawn impression on any flat surface.

According to the principles of the invention, the bi-directional shaped articles may be attached or otherwise attached to any planar support structure.

Figure 1 shows the shaping part in a partial partial section showing the lower part of the shaping mold 4 with the cellulose sheet 5 thereon and the upper part of the shaping mold generally designated by reference number 10. The upper part of the shaping mold 6 has a shaping mold pattern 7 in its lower surface. the shape of which is completed by a convex shaping pattern defined by the pattern of the lower part of the shaping mold 4, and the plate 5 is formed therebetween to conform to the pattern between the shaping parts 4 and 6. The paneling 10 is bi-directionally formed as shown in Figs. 1 and 2 between the convex lower part of the mold 4 and the upper part of the mold 6 to provide raised panels 12 in the shaped article 10, including centrally spaced flat portions of panels 13 and contour walls generally indicated by number 14, with raised outer corners 15 on the outside pan surface which correspond to the contours substantially identical to the raised contours of the lower portion of the shaping mold 4. The bidirectionally shaped panel 10 may be secured, for example, by abutting or with fastening means such as nails or screws, on a suitable flat surface such as the wall surface of the room inside a building. . The lower portion of the shaping mold 4 has substantially the same overall outline as the top surface of the paneling 10, except that the lower portion of the shaping mold 4 is, given the dimensions of the raised panel, slightly smaller horizontally, which allows the use of a shaped cellulose board 5 with some thickness to obtain the raised panel relief pattern shown in Fig. 2. The upper part of the shaping mold 6 includes the pattern of the shaping mold 7 having dimensions to complement the top surface of the raised panel structure 12 and may have a smooth contour or may include a concave structure (not shown) for the purpose of obtaining an embossing imitating the grain of the wood.

The panel of the wainscot 10 is formed by a recess in the pattern of the shaping mold between the portions 4 and 6 substantially horizontally arranged such that the upper major surface is horizontal, corresponding to its orientation during shaping, and tends to be a vertical, non-horizontal, position of the shaped article as this is the case of the wainscot panel 10 of Figs. 2-7. The shaped, outer surface of the wainscot panels 10 with the profile raised upwards is positioned vertically (with the profile raised outwards) between the base of the wall 16 and the batten at the height of the handrails of the chairs 18, as shown in Fig. 6. An exemplary wainscot panel 10 shown in Fig. 2 , in a preferred embodiment of the invention comprises one or more raised panels 12 which are shaped to provide contour walls substantially designated 14, integral with and surrounding a centrally located flat portion of the raised panel 13, and rectangular contour walls 14 integral with and surrounded by appropriately flat, vertical stiles 20 and 22 and horizontal stiles 24 and 26 located on a common surface allowing the lower surface of the stiles 20, 22, 24 and 26 to be adhesively attached to a flat surface as shown in Figs. 3 and 6.

In the paneling panel 10, best shown in Figs. 2-4, bi-directional shaped wall portions of rectangular shape 14 surround the centrally located, flat portion of the panel 13 and are interconnected to the outer edges 27 of the flat portion of the panel 13 by sloping walls 28 provided by the panel. between them. The panel profiles shown in Fig. 5 and Fig. 6 show that the contour walls 14 consist of a wall portion 30 that is integral with and extends upwardly from an adjacent horizontal or vertical stile (24 as shown in Fig. 5) underneath. an angle of from about 25 ° to about 35 ° above the horizontal portion (shaped horizontally). A portion of the wall 30 is curved downward in a rectangular contour wall portion 32 integrated at the outer end with the flat portion of the raised panel 13 at the outer edges 27 (Fig. 2 and Fig. 5) of the flat portion of the raised panel 13. Each of the four rectangular contour walls 14 that form the bidirectional shaped rectangles of each of the raised panels 12 have identical contours. According to a preferred embodiment of the invention, the U-shaped contour wall portion 32 is formed such that the innermost bottom face 34 (mounted on the wall) of the contour wall portion 32 lies in the same plane as the lower face on the basis of the U-shape. 36 horizontal and vertical stiles 20, 22, 24 and 26, so that the bottom surface 34 of the U-shaped contour part of the wall 32, on the basis of this shape, contacts

Is fixed and can be attached to wall 37 as a structural support when positioned as shown in Fig. 6.

The articles are formed from a board consisting of cellulosic fibers and a thermosetting binder, such as urea-formaldehyde, melamine-formaldehyde and / or phenol-formaldehyde binders commonly used in the manufacture of fibreboards. The board should contain about 80% fibrillated, refined cellulose fibers, or even 100% given the total dry weight of the fibers in the board 5. The fibers are mechanically refined from pieces of wood, preferably using a steam pressure ranging from about 80 to 120 psi or from about 100 to 110 psi, and about 105 psi is preferred. A vapor pressure greater than 120 psi when refining cellulosic fibers results in highly refined fibers that are suitable for the invention, but the cost of such refining would be too high for common use.

Refining of cellulosic fibers will provide cellulosic fibers that can be dry-folded into a single sheet of cellulosic fibers having a base weight ranging from about 10.4 to about 10.2 kg / m ² . Shaping in a hot press at a temperature of about 196 ° C to 232 ° C and a maximum pressure in the range of about 550 to about 850 psi causes the shaped articles to have a specific weight of from about 0.96 to about 1.08, preferably from about 0.98 to about 1.08. about 1.06 and preferably from about 1.00 to about 1.04. In both smooth and textured products that are convex profiled, the surface density and strength are increased by reducing the diameter at the highest point of the pattern profile to about 1.02-1.08 specific gravity, with an intended specific gravity of 1.02 to 1.04. The flat surface geometry surrounding the profile zones is compressed to a slightly lower specific gravity from 1.00 to 0.98 by slightly enlarging the diameter in these zones.

In another important exemplary embodiment of the invention, the bi-directional shaped panels 10 may be produced in multiple widths as shown in Figure 3, e.g., a shaped panel 10A approximately 120 cm wide and having three raised panels 12, a panel 10B approximately wide. 40 cm with a single raised panel 12, and a flat panel 10D about 20 cm wide that can be easily cut lengthwise to allow a wall covering. Each of the panels 10A, 10B, 10C and 10D is of the same height, for example about 80 cm - the standard height of the paneling. As shown in Fig. 3, panels, for example 10B or 10C, can be placed under the windows 40 by turning the panel (10B as shown in Fig. 3) 90 ° so that the raised panel 12 is horizontally aligned and, if necessary, when the windows are closer to the floor, panel 10C may be used instead, together with one or two flat panels 10D above and below panel 10C.

The paneling set shown in Fig. 2 can be easily installed by anyone, starting from the center of the room or directly below the center of the window and arranging panels 10B and / or 10C respectively, flat panels 10D with a width of 20 cm are suitable to cover all walls to their defined ends. across the room corners and can be cut exactly to cover the wall completely.

According to another aspect of the invention, electric light switch plates (not shown) and mains socket covers substantially and collectively designated by reference number 40 (Fig. 7) are provided in the assembly shown in Fig. 3. They are rectangular and their outermost, vertical walls 42. are at least as high as the raised contour walls 41 and the flat portions of the raised panels 13 belonging to the panels 12, so that wherever light switches and electrical outlets are present in the paneling panels 10, a hole is cut in the panel 12 of the same size as a switch or socket 40 and socket 40 are inserted into a panel against a wall without exposing a cut panel as the cutouts in panel 12 will lie flush with the outermost walls 42 of socket 40 as shown in Figure 8.

Claims (66)

Patent claims 1. A bi-directional wood composite product formed from a mat of refined cellulose fibers and a suitable high-tack binder that combines the cellulose fibers into a solidly structured product with a specific gravity ranging from about 0.96 to about 1.08, characterized in that the product has a first portion of a flat surface (20, 22, 24, 26) surrounding an outwardly projecting second flat surface portion (13), the first and second planar surface portions (13, 20, 22, 24, 26) having a substantially uniform density and the second flat part The surface (13) has a plurality of outer corners (15) that simulate the surface structure of natural wood, the coplanar rear surface (34, 36) of the product allowing it to abut against a flat surface substrate (37), and that the article has an inner and upward contoured portion (14) interposed between and interconnecting the first and second planar surface portions (13, 20, 22, 24, 26), the contoured portion (14) having a higher density than that of the first and a second flat surface portion (13, 20, 22, 24, 26). 2. Wood composite product according to claim The process of claim 1, wherein the article comprises less than 5% by weight of a resin binder. 3. Wood composite product according to claim 1, The method of claim 2, wherein the resin binder is evenly distributed throughout the product. 4. Wood composite product according to claim 1, The process of claim 3, characterized in that the article does not contain a thermoplastic coating material on the cellulose board and does not contain a resin-impregnated paper coating. 5. Wood composite product according to claim 1, The process of claim 1, wherein the cellulose fiber board is produced by a dry process and has smooth, flat rear portions. 6. Wood composite product according to claim 1. The method of claim 1, wherein the planar wall surface (37) is attached to the coplanar rear surface (34, 36) of the article by means of fasteners or an adhesive without the use of adjusting spacers between the planar wall surface (37) and the coplanar rear surface (34, 36). of the product. 7. Wood composite product according to claim 1, The process as claimed in claim 1, characterized in that the outwardly projecting contoured portion (14) projects outwardly from the surrounding first flat-surface portions (20, 22, 24, 26) by a distance of 5 to 10 mm. 8. Wood composite product according to claim 1, The process of claim 1, wherein the cellulose board comprises at least 40% by weight of softwood fibers, based on the total weight of the cellulose fibers in the product. 9. Wood composite product according to claim 1, The process of claim 1, wherein the softwood fibers are derived from pine, spruce and a mixture thereof. 10. Wood composite product according to claim 1. The process of claim 8, wherein the cellulose fibers constitute approximately 100% by weight of softwood fibers. 11. Wood composite product according to claim 1, The process of claim 1, characterized in that the contoured portion (14) projects outward and inward from the surrounding first portion with a flat surface (20, 22, 24, 26) at an angle ranging from 25 ° to 35 °. 12. Wood composite article according to claim 1. 11. The method of claim 11, characterized in that the contoured portion (14) projects outward and inward from the surrounding first portion with a flat surface (20, 22, 24, 26) at an angle ranging from 30 ° to 35 °. 13. Wood composite product according to claim 1, The method of claim 1, characterized in that the specific weight of the article at the highest point in the contoured portion (14) is higher than the specific weight of the first planar portions (20, 22, 24, 26). 14. Wood composite article according to claim 1, 13. The method of claim 13, characterized in that the specific gravity of the article at the highest point in the contoured portion (14) ranges from 1.02 to 1.08, and the specific gravity of the first planar parts (20, 22, 24, 26) ranges from 0.98 to 1.00. 15. A method for producing a bi-directional shaped wood composite article in which the cellulose fiber mat and the resin binder are placed on a substantially horizontal, lower shaping mold, characterized in that the lower shaping mold (4) has flat surface portions surrounding the projecting upwardly toward the end of the mold. on top, a contour pattern imitating a surface structure and having a plurality of outer corners, then the mat (5) is pressed by pressing against the upper shaping mold, which is internally contoured on the bottom surface (7) contacting the mat, and this inner pattern in the upper shaping mold ( 6), has a shape complementary to the contour pattern imitating a surface structure and projecting upwardly from the lower shaping mold (4), so that the density of the mat (5) increases at points corresponding to the upwardly projecting surface structure pattern in relation to mat density (5) at points corresponding to parts with flat It is pressed at the appropriate temperature and pressure to structurally consolidate the mat into a specific gravity product ranging from about 0.96 to about 1.08. 16. The method according to p. The process of claim 15, wherein the article comprises less than 5% by weight of a resin binder. PL 201 703 B1 17. The method according to p. The method of claim 16, wherein the resin binder is evenly distributed throughout the product. 18. The method according to p. The method of claim 17, characterized in that the article does not contain a thermoplastic coating material on the cellulose mat (5) and does not contain a resin-impregnated paper coating. 19. The method according to p. The process of claim 15, characterized in that the cellulose fiber mat (5) is produced during a dry process and has a smooth, flat rear surface. 20. The method according to p. The method of claim 15, wherein the flat wall surface (37) attaches to the rear surface (34, 36) of the article. 21. The method according to p. The method of claim 20, wherein the planar wall surface (37) is attached to the planar rear surface (34, 36) of the article without the use of adjusting spacers between the planar wall surface (37) and the planar rear surface (34, 36) of the article. 22. The method according to p. The contour panel according to claim 15, characterized in that the outwardly projecting contour panel (13) is shaped to project from the surrounding flat surface parts (20, 22, 24, 26) a distance of 5 to 10 mm above the surrounding flat base. 23. The method according to p. The process of claim 15, wherein the cellulose board comprises at least 40% by weight of softwood fibers, based on the total weight of the cellulose fibers in the product. 24. The method according to p. The method of claim 23, characterized in that the softwood fibers are derived from pine, spruce and a mixture thereof. 25. The method according to p. The process of claim 24, wherein the cellulosic fibers constitute approximately 100% by weight of softwood fibers. 26. The method according to p. 15. The method according to claim 15, characterized in that the contour portion is formed as a protruding and concave with respect to the surrounding portion with a flat surface (20, 22, 24, 26) at an angle ranging from 25 ° to 35 °. 27. The method according to p. 26, characterized in that the contour portion (14) is formed as a protruding and concave with respect to the surrounding flat-surface portion (20, 22, 24, 26) at an angle ranging from 30 ° to 35 °. 28. The method according to p. The method of claim 15, characterized in that the upper and lower parts of the shaping mold (4, 6) are spaced less at the highest points in the convex contours than on the flat surfaces surrounding the convex contours, such that the product has a greater specific gravity at the highest points of the contoured part (14) than on parts with flat surfaces (20, 22, 24, 26) surrounding convex contours. 29. The method according to p. The method of claim 28, characterized in that the specific gravity at the highest points of the convex contoured portion (14) ranges from 0.98 to 1.00, and the specific gravity of the portions with flat surfaces (20, 22, 24, 26) surrounding the contoured portion (14) ranges from 0.98 until 1.00. 30. A method of manufacturing a raised contoured panel that is mounted on a flat surface, wherein the wood composite article is shaped according to claim 1, 1, then the raised panel (12) is separated from the surrounding flat-faced parts (20, 22, 24, 26). 31. The method according to p. The process of claim 28, wherein the cellulosic fibers constitute approximately 100% by weight of softwood fibers. 32. A paneling assembly comprising a first and a second composite wood product according to claim 1; The method of claim 1, wherein both the first and second composite wood products (10, 10A, 10B, 10C) have the same height but different width and both have outwardly projecting contour panels (12) of the same height and different width, and a third, flat wood composite product (10D), where all three composite elements (10A, 10B, 10C, 10D) can cover the entire wall between the wall base plate (16) and the wall trim at the height of the chair handrails (18) by cutting only a third flat panel (10D) to the correct size at the corner of the wall. 33. A paneling assembly comprising a first and a second composite wood product as defined in claim 1; The method of claim 13, characterized in that both the first and second composite wood products (10, 10A, 10B, 10C) have the same height but different width and both have outwardly projecting contour panels of the same height and different width, and a third, flat a wood composite product (10D), whereby all three composite elements (10, 10A, 10B, 10C, 10D) can cover the entire wall between the wall base plate (16) and the wall trim at the height of the chair railings (18) by cutting only the third flat panel (10D) to the correct size at the corner of the wall. 34. A paneling kit as claimed in claim 1. The method of claim 32, wherein a fourth wood composite product (10, 10A, 10B, 10C) is provided having a plurality of spatial outwardly projecting panels. And being wider than the first, second, and third wood composite articles (10, 10A, 10B, 10C, 10D). 35. A paneling set as claimed in claim 35. The method of claim 33, characterized in that a fourth wood composite product (10, 10A, 10B, 10C) is provided having a plurality of spatial outwardly projecting contour panels (12) and being wider than the first, second, and third wood composite product (10, 10). 10A, 10B, 10C, 10D). 36. A paneling kit as claimed in claim 1. 32, characterized in that a rectangular electrical socket cover (40) is provided having slots adapted to cover the rectangular area surrounding the electric socket, while the electric socket remains accessible for connection of any electrical appliance, and having side walls (42) which are at least high to the height of the protruding contour panels (12) being part of the two-way shaped wood composite product (10, 10A, 10B, 10C), so that the slots formed to obtain an electrical socket cover in the panel (12) of the wood composite product (10, 10A, 10B, 10C), are invisible and come into contact with the cuts in the composite wood product (10, 10A, 10B, 10C) in which they are located. 37. A paneling set as claimed in claim 1, The method of claim 33, characterized in that there is provided a rectangular electrical socket cover (40) having slots adapted to cover the rectangular area surrounding the electric socket while the electric socket remains accessible for connection of any electrical appliance, and having side walls (42) high at least to the height of the protruding contour panels (12) being part of the two-way shaped wood composite product (10, 10A, 10B, 10C), so that the slots formed to obtain the electrical socket cover (40) in the wood composite product panel (10, 10A) , 10B, 10C) are invisible and come into contact with cuts in the wood composite product in which they are located. 38. A two-way shaped wood composite door cladding comprising a shaped molded wood composite panel having a first face adapted to be external fixable and opposite, a second face adapted to be internal fixable, and it is attached adhesively to the surface characterized in that the panel comprises a main part with flat faces (20, 22, 24, 26), at least one flat part of the panel (13) lying in a plane remote from the plane of the main part with flat faces (20, 22, 24, 26), and extending outwards a contour wall (14) surrounding the flat portion of the panel (13) and interconnecting and integral with the main portion of the flat and flat panel portion, and the contour wall (14) extends outwardly from and correspondingly to the first surface. 39. Door cladding according to Claim 38, characterized in that the contour wall (14) has an apex. 40. Door cladding according to Claim 39, characterized in that the vertex has a rounded upper surface. 41. Door cladding according to claim 1, 38, characterized in that the contour wall (14) comprises a plurality of raised flat steps positioned between the flat-faced main portion (20, 22, 24, 26) and the rounded top surface. 42. Door cladding according to Claim 38, characterized in that the contour wall (14) comprises a first contour portion adjacent the flat-faced main portion (20, 22, 24, 26) and a second contour portion (32) adjacent the flat portion of the panel (13). 43. Door cladding according to Claim 42, characterized in that the first contour portion (14) extends outward from the first surface and the second contour portion (32) extends inward with respect to the flat portion of the panel (13). 44. Door cladding according to Claim 43, characterized in that the flat part of the panel (30) is located outward with respect to the main part with flat faces (20, 22, 24, 26). 45. Door cladding according to Claim The contour wall (30) extends outward from the first surface at an angle of from about 25 ° to about 35 °. 46. Door cladding according to Claim 38, characterized in that each portion of the raised flat panel (13) is rectangular. 47. A door facing according to Claim 46, characterized in that the contour wall is rectangular in plan. PL 201 703 B1 48. Door cladding according to Claim 38, characterized in that the flat-faced main portion (20, 22, 24, 26) has a first transverse dimension, the contour wall (14) has a second transverse dimension, and the second diameter is smaller than the first. 49. Door cladding according to Claim 14. The panel according to claim 38, characterized in that the panel consists of 40% by weight of wood fibers from the group consisting of pine and fir. 50. A door cladding according to Claim 38, characterized in that the panel is made of fibreboard. 51. A method of forming a two-way shaped wood composite door trim in steps, characterized by first introducing a shaping mold having an upper shaping shank having a flat portion and at least one shaping recess, and a lower shaping shank that having a portion. flat and at least one convex contour pattern to complement the shaping cavity, then place the cellulose mat between the upper and lower shaping mold shafts and compress the cellulose mat therebetween, and heat it to a temperature to form a door cladding having a contour portion and a flat portion characterized by having a contoured portion (14) located outwardly relative to the first surface of the planar portion (20, 22, 24, 26) adapted to be applied externally and opposed to the second surface adapted to be used internally and secured to a surface (37), in which the flat part ( 20,22,24,26) has a first lateral dimension and the contour portion (14) has a second lateral dimension smaller than the first. 52. The method of claim 51, characterized in that the cellulose sheet is compressed to a suitable gravity in the range from 0.96 to 1.08. 53. The method of p. The process of claim 51, wherein the cellulose sheet is heated to a temperature from about 196 ° C to about 232 ° C. 54. The method of p. The method of claim 51, wherein pressure is applied to the cellulose sheet from about 550 psi to about 850 psi. 55. The method of p. The process of claim 51, wherein the cellulose board comprises at least 80% by weight of fibrillated cellulose fibers which come from the group consisting of pine and fir. 56. The method of p. The process of claim 51, wherein the thermosetting binder is selected from the group consisting of melamine-formaldehyde, phenol-formaldehyde and urea-formaldehyde resins. 57. A bi-directionally shaped shaped composite wood panel panel comprising a major planar portion having a first surface mountable exterior and an opposite second surface mountable interior that is adhesively attached to the surface, characterized in that the major planar portion (20, 22 , 24, 26) has a first transverse dimension, the flat part of the panel (13) lying on a plane remote from the plane of the main flat part (20, 22, 24, 26) and the contoured part (14) extending outward from and correspondingly to of the first face and is connected and integrated with the main flat part (20, 22, 24, 26) and the flat part of the panel (13), and the contoured part has a second lateral dimension smaller than the first. 58. A two-way shaped panel as defined in claim 58. 57, characterized in that the contour portion comprises a rounded upper portion. 59. A two-way shaped panel as defined in claim 59. 57, characterized in that the flat part of the panel is adapted to be mounted external to the main flat part (20, 22, 24, 26). 60. A two-way shaped panel as defined in claim 60. 57, characterized in that the contour portion comprises first and second contour portions (30, 32) and the first contour portion (30) has a rounded upper surface and is approximated to the main flat portion (20, 22, 24, 26), and the second contour portion (30). the outline (32) is approximated to the flat part of the panel (13). 61. A door comprising first and second door claddings, each having a first inner surface attached to the door carcass and a second outer surface, characterized in that at least one of the door claddings has a major flat surface (20, 22, 24, 26). ) and at least one planar portion of the panel (13) lying on a plane remote from the plane of the main planar portion (20, 22, 24, 26), and an outwardly contoured wall (14) surrounding the planar portion of the panel (13) and is connected by and integrated with the main flat part The panel (20, 22, 24, 26) and the flat portion of the panel (13), and the contoured wall (14) extends outwardly from and correspondingly to the first surface. 62. The door as claimed in claim 62 61, characterized in that the main flat surface (20, 22, 24, 26) has a first transverse dimension and the contour wall (14) has a second transverse dimension and the second transverse dimension is smaller than the first. 63. The door of claim 1 61, characterized in that the flat part of the panel (13) is adapted to be mounted external to the main flat part (20, 22, 24, 26). 64. The door of claim 1 61, characterized in that the contour wall (14) comprises a first portion which has a rounded top surface approximated to the main flat portion (20, 22, 24, 26) and the second portion to a portion of the panel (13). 65. A bi-directional shaped wood composite door cladding comprising a shaped hard fiberboard panel which has a first surface adapted to be laid as an exterior and an opposite second surface adapted for use as an interior which can be adhesively attached to the surface, characterized in that the panel has a main face. a flat part (20, 22, 24, 26), at least one flat panel part and an outwardly projecting contoured wall (14) surrounding the flat part of the panel and connected and integrated with the main flat part (20, 22, 24, 26) and the flat portion of the panel (13) and the contour wall (14) extends outward from and corresponding to the first surface. 66. A bidirectionally shaped wood composite door cladding comprising a shaped wood composite panel that has a first surface adapted for external use and an opposite second surface adapted for internal use that can be fitted to the surface, characterized in that the panel comprises a weight of approx. about 8% resin binder and has a main flat part, at least one flat panel part, and an outwardly projecting contoured wall surrounding the flat panel part and joined and integrated with the main flat and flat panel part, and the contour wall extends outward from and respectively to the first surface.